Warp pile fabric



W. S. NUTTER WARP PILE FABRIC Nov. 7, 1944.

, 2 Sheets-Sheet 2 Filed Oct. 8, 1943 SM MM Patented Nov. 7, 1944 UNITED STATES PATENT OFFICE, 4

` a 1 i 2362,299 a a p WAltP 'mE minne y William s; Nutter, Sanford; Ma in'e- V g Application ctober8, 1943, Serial No.` 505,461'

f 7 Olaims. (01. 28-80) This invention relates to pile fabric of that type.

generally used for upholstery in automobiles, railway cars, busses; furniture and the like and which has also found an extensive use for'carpe'ting and rugs. This type of pile fabric is best' made with the pile formed from the warps and with these -pile warps composed wholly or in part of mohair. Mohair is highly advantageous for this purpose because of its great durability and resistance to wear. But mohair 'is relatively a very expensive fiber and its Conservation is, therefore,`important. v

A chief object of the present inventionis to present a mohair warp pile fabric of the type involved in which a number of the pile tufts and consequently a minimum: amount of the mohair fiber Component is employed, while at the same time the required appearance of the fabric is secured, the optimum wearing quality of the fiber is brought out, and qualities hitherto found objectionable but considered inherent in` this type of pile fabric are eliminated or obviate'd.

A further object ofthe invention 'is to' present such a mohair warp pile fabric in which the'pile component of the fabric is so'arrangedas to meet most eftlciently the'requirements for upholstery and similar purposes.

Afurther object of the invention is to present such a mohair or mohair containing pile fabric j in which the pile component. of the fabric is'so arranged as to allow great flexibility of the pile tufts with consequent low friction resistance and high wearing'qualityof'the pile. e 'In this type. of moha'ir'warp pile fabric to which the invention relates 'the ground'- or base portion is commonly composed'fof cotton warps and wefts, and the pile tuftsformed from the pile warp are of V-shape and extend around 'under and project upward from the wefts of the' ground. This" type of fabric may bewoven single 'With the pile warps formed into loops which may be left uncut but are usually cut to form the V-tufts. But usually this type of fabric is woven double with the pile warps` runningback and forth between the basesj of the two fabrics withv thepile warps 'cut 'midwaythe bases of the two fabrics as the weavingoperationproceeds. After, this type of fabric, whether woven single` or double, has been taken from the loom, the `V-tufts are insecurely held in the ground. Consequently it has been the practice to provide a thin coating-of a suitable adhesive such as a natural or artificial rubberdispersion pre-vulcanized or subsequently vulcanized or a pyroxylin or other solutionwhicli is'applied to the back of the'ground in' asultable manner. so as to impregnate the ground andthe portion of the piIe-tuftsembedded in the ground. This coating acts' firmly to secu-re the piletufts in place and is so applied asnot to forma continuous sheet but rather to leave open and unobstructed most of the spaces between the'interlaced warps and wefts of -the ground. This enables air to pass back 'and forth through the ground or, as it is termed in this art, permits "breathing of the fabric back. The methods and apparatus'employed for-thus weaving andcoating such warp pile fabrics are now well known and familiar to those skilled in this art and therefore here need no 'detailed description or illustration. p

Itwill be seen that the pile tufts in the fabric extend in longitudinal rows and a rowj' of pile tufts in this invention'may be either a single series of tufts formed'from a `single pile warp or i as herein termed a duplex row composed of two parallel series of tufts formed from two pile warps with a pair' of groundwarps interposed.

In this invention the ground warps following each row or duplex row of the pile tufts in the widthwise repeat are of two sizes, one relatively large and one relatively small and Where the row of pile tufts is of the duplex form the relatively small ground'warps are preferably of the same size as the ground warps interposed in the duplex row. Most satisfactoryresults have been secured by, employing-for the relatively' large ground warpsafifty per cent increase in sizeover the relatively small ground warps, and this is readily v secured by employing for the relatively small ground Warpsa two-ply cottonyarn and for the relatively large athree-ply'cotton yarn ofthe same count. The position ofthe relatively large and relativelysmall groundwarps inthe repeat may be varied somewhat `as ill b'e hereinafter indicated, but in all-cases the arrangement is I such that the relatively large ground warps function both to stabilize the fabric and to support the rows of pile tufts so that the fabric presents the required feel, body and uniform even -appearance of the pile face whileemploying a minimum amount of pile yarn. 'i h In the widthwise repeat the total number of ground warps, including the relativelylarge and,

relatively small ground warps following *the row of pile tufts, must be at least threetimes and not more than four times the number of pile warps to obtain the desired result: -Thus where the row is single there will naturallybe four, and where the row is double either' four o'r six, following the row of pile tufts. The stabilizing and supporting with the proportions exaggerated. No attempt is `made to illustrate the adhesive coating employed because its relation to the fabric is Well known in the art and cannot be accurately shown.

In the drawings Figs. 1 to 4 inclusive illustrate preferred forms of the fabric in'which the minimiun amount of mohair pile yarn that will give the required appearance and quality is employed. Figs. 5 and 6 illustrate forms of fabric also embodying the invention but in which a somewhat larger amount of mohair`- 'pile- -approximately one-third-is employed. l

Fig. 1 illustrates a single widthwise repeat of a fabric in Which a duplex rowof the pile tufts is followed by six ground warps with the first and last of the relatively large size and the others of the relatively small size.

`Fig. 2 illustrates 'a construction similar to that of Fig. 1 but with the first and last of the ground warps following the duplex row of pile tufts of the relatively small size and the others of the relatively large size.

Fig. 3 illustrates a single widthwise repeat of a fabric in which two staggered Single rows of pile tufts are each followed by four ground warps with the first and last of the relatively large size and the others ofthe relatively small size.

Fig. 4 illustrates a construction similar to that of Fig. 3 but with the first and last of the ground warps of the relatively small size and the others of the relatively large size. f

`Fig. 5 illustrates a single widthwise repeat of a fabric in which two staggered duplex rows of pile tufts are each followed by four ground warps with the first and last of the relatively large size and the others of the relatively small size.

Fig. 6 illustrates a construction similar to that of Fig. 5 but with the first and last of the ground warps following the duplex rowof pile tufts of the relatively small size and the others of the relatively large size. i

Fig. 7 is a view based upon a'microphotograph ascazoe row of pile tufts give the requisite support so that a very firm and stable fabric is produced.

In Fig. 2the construction is similar to that of Fig. 1 excepting that in this case the six ground warps 22, 23, 24, 25, 23, and 21 following the duplex row of tufts in the repeat have the relatively small size ground warps 22 and 21 immediately adjacent the duplex row of tufts and the other ground warps 23, 24, 25, and 25 of the relatively large size. But it is found that with only one'of the relatively smallground warps lying between the row of tufts and the following relatively large siZe ground warps that the required stabilizing and supporting function is still practically seof a small section of pile fabric embodying the construction shown in Fig. 3 and taken in section along the line 'l-l of Fig. 3.

In the construction shown in Fig. 1 the duplex row" of pile tufts is employed, the tufts 8 being staggered with respect to the tufts 9, that is, the tufts 8 extend around under the ground wefts' |0 and l2 while the tufts 9 extend around under the ground wefts I I and 13 with the interposed ground warps |4 and I5 in each case extendin over the weft under which the adjacent tuft extends. Following this duplex row of pile tufts are the six ground warps 16, ll, l8, IQ, 2D, and 21 with the ground warps IG and 2l immediately adjacent the duplex row of the relatively large size and the others ll, 18, 19, and 20 of the relatively small size. When the elements of this fabric are compacted in finished form the relatively large ground warps give the required stabilizing effect and coming immediately adjacent to the duplex cured. In Fig. 3 a single row of pile tufts 28 and a 'staggered row of tufts 29 is illustrated and each row in the repea't is followed by four ground warps with those of relatively large size immediately adjacen the row of tufts and the others of relatively small size. Thus the row of tufts 28 is followed by the fourground warps 30, 3I, 32, and 33 with the ground warps 30 and 33 of the large size and the others 3! and 32 of the small size. Following the row of tufts 29 is a similar set of ground warps 34, 35,36 and 31.

In Fig. 4 the construction is similar to that of Fig. 3 but in this case the first and last ground warps 38 and 39 following a row of tufts and thus lying immediatelyadjacent to each of the spaced rows is of the relatively i small size while the others 40 and 4| are of the relatively large size.

The constructions shown in Figs. 5 and 6 are generally similar to those shown in Figs. 3 and 4 respectively except that in this case duplex rows of pile tufts are employed in'stead of single rows thus increasingabout a third the amount of pile in a given'area of fabric but still maintaining a low quantity of mohair. In Fig. 5 the pile tufts 42 are staggered with respect to the pile tufts 43 and fornrwith the interposed ground warps 44 and 45 one duplex row while the pile tufts 46 and 41 of the next duplex row are staggered respectively with respect to the pile tufts 4'2 and 43 of the first duplex row in the repeat. Here again each duplex row in the repeat is followed by four ground warps as for example 48, 49, 50, and l with the first and last 48 and 5! or those immediately adjacent the spaced rows of 'the relatively large size and the others 43 and 5D of the relatively small size. In Fig. 6 the construction is the same excepting that in the case of the four ground warps following each duplex row of tufts in the repeat, as for example 52, 53, 54, and 55, the first and last 52 and 55 or those immediately adjacent the spaced duplex row of tufts are of the relatively small size and the others 53 and 54 of the relatively large size. o

In the construction of Figs. 1, 2, 5, and 6 the ground warps beginning With'the second in the repeat are woven as flats in pairs in alternation over and under successive wefts but this is not essential and is varied' as indicated in Figs. '3 and 4.

Fig. 7 is a close representation of a microphotograph of a warp pile fabric in Which the pile warp contained a substantial amount of mohair fiber and in which the fabric is constructed in accordance with the present invention. 'There is here represented a fabric having the construction illustrated diagrammatically in Fig. 3. The pile fabric from which the microphotograph was taken was a low pile upholstery fabric, and the drawing represents an enlargement of approximately twenty-five times. It wll be seen from this figure'that the-pileco'mponent of the fabric composedof the pile tufts each containing mohair is so'arranged or positioned that the pile tufts are highly flexible and have spread or fanned'out to afhigh degree. The ground warps which follow the rows of tufts in the repeat afford space for the pile tufts thus to spread or fan out while the inclusion in this group of the large size warps gives the -necessary stabilization to the fabric and support to the tufts. Were it not for the spaces thus provided the fibers of the pile tufts Would stand up substantially erect from the groundor base as in this type as heretofore constructe'd. With the pile tufts thus erect the pressure of the body of a person is taken chiefly upon the ends of the fibers and wear is mainly on the fiber ends. Anyone who has sat upon an ordinary plush upholstered automobile seat recognizes the grip of the fabric on the clothing and the resistance aiforded" to lateral shifting of the body. With the construction of this invention wherein the tufts of pile spread or fan out as illustrated in Fig. 7 the pressure 'of the body is taken largely by the side surfaces of the pile fibers rather than by the pointed ends. This practically eliminates the undesirable grip of thepile on the clothing and enables lateral shifting of the body readily to take place. It will be seen that the pile tufts thus fanned or spread out are highly flexible and that due to this flexibility and the consequent position of the fibers there is less frictional resistance thus i reducing wear and allowing for free movement of the body or whatever may be moved upon or against the pile when in use. In this connection the abrasive tests commonly employed on pile fabrics have been made and show that pile fabrics made in accordance with this invention withstand the abrasive action to a remarkable extent and far beyond anything hitherto obtainable with this type of fabric. Tests also made with respect to theangle of slope show that test Objects placed upon the pile fabric of this invention start to move at an exceedingly low angle or slope thus indicating the low friction 'resistance of the pile face. p

With the 'constructions of the invention whereby four ground warps follow the row of pile, as

for example in Figs. 3, 4, and 7, the pile tufts spread or fan out sufiiciently to present a substantially even and continuous body of pile *and pile face while with the construction employing six such ground warps a slight ribbedeffect appears in the face but with the same advantages due to the position of the pile fibers. This gives what may be termed a Bedford cord effect familiar in fiat and corduroy fabrics but not before successfully employed in V-weave pile fabrics.

permitting breathing, 'in which the repeat widthwise of the fabric consists of a row of the'vpile tufts followed by :a suflicient number of ground warps oftrelatively large and relatively small size 'to present at least three and not more than four :times as'many ground warps as pile warps in the repeat. with the ground warps immediately adjacentfithespaced rows of tufts' of: the one sizeand theremainder of the ground warps between said spaced-rows of the other size, the relatively large ground warps a-cting to stabilize the fabric'and support-the rows of tufts. I

ground warps acting to stabilize the fabric and p support the rows of tufts.

3. An upholstery pile fabric of that type in which the bases of V-pile tufts' composed of or containing a substantial proportion of mohair' are adhesively secured to the ground with open- Furthermore in all cases the breathing quali ity of the fabric in this invention is enhanced f and dust and dirt readily removed since it is not wedged into erect upstanding pile. i

The term upholstery as used in the claims is to be understood as not restricting the claims to the particular use to which the fabric of the invention may be put and includes its use as for carpeting and rugs as pointed out in the beginning of this specification.

Having thus described the'invention, what is claimed as new, and desired to be secured by Letters Patent, is:` p

1. An upholstery pile fabric of that type in which the bases of V-pile tufts composed of or containing a substantial proportion of mohair are adhesively secured to the ground with openings between the warps and wefts of the ground permitting breathing, in which the repeat widthwise of the fabric -consists of a single row of the V-pile tufts followed by four ground warps, two

of relatively large size and two of relatively small size, with the two immediately adjacent the spaced rows of tufts of the small size and the other two of the large size, the relatively large -groun d warps acting to stabilize the fabric and support the rows of tufts. f

4. An upholstery pile fabric of that type in which the bases of V-pile tufts composed of or containing a substantial proportion of mohair are adhesively secured to the ground with openings between the warps and wefts of the ground permitting breathin g, in which the repeat widthwise of the fabric consists of a duplex row of the V-pile tufts and interposed pair of groundwarps followed by six ground warps, of relatively large and relatively small size, with the first and last of said six' ground warps immediately adjacent the spaced duplex rows of tufts of the one size and the other four of the other size, the relatively large ground warps acting to stabilize the fabric and support the rows of tufts.

5. An upholstery pile fabric of that type in which the bases of V-pile tufts composed of or containing a substantial proportion of mohair are adhesively secured to the ground with openings between the warps and wefts of the ground permitting breathing, in which the repeat widthditely adjacent the spaced duplex rows of tufts of relatively small size and the other four of relatively large size, the relatively large ground warps acting to stabilize the fabric and support the rows of tufts.

6. An upholstery pile fabric of that tyipe in whi-ch the bases of V-pile tufts composed of or containing a substantial proportion of mohair are adhesively secured to the ground with openings 4- asemaa between the warps and wefts of the ground permitting breathing, in which the repeat widthwise of the fabric consists of a. duplex row of the V-:pile tufts and interposed pair of ground warps followed by four ground warps, two of relatively large size and two of relatvely small size, with the two immediately adjacent the spaced duplex rows of tufts of the one size and the other' two of the other size, the relatively large ground warps acting to stabilize the fabrio and support 10 the rows of tufts.

7. An upholstery pile fabrio of that type in which the bases of V-pile tufts composed of e or containing a -sub'stantal proportion of mohair areadhesively Secured to the ground with openings'between the war-ps and wefts` of the ground permitting breathing, in which the repeat widthwise of the fabric consists of a duplex row of 'the V-pile tufts and interposed pair of ground. warps followed by four ground warps with the first 'and last of said four ground Warps immediately adjacent the spaced duplex rows of tufts of relatively small size and the other two of rele` tively large size, the relatively large ground warps actingto stabilize the fabric and support the rows of tufts;

' i WILLIAM S. NUTI'ER. 

